Control Global

Hunter Vegas from Wunderlich Malec and Ned Espy and Roy Tomalino from Beamex present a two-part ISA webinar on the basics, crucial issues and best practices for successful pressure calibration.

As natural forces go, pressure is pretty straightforward. It involves less mysterious physics than electromagnetism, it's easier to observe than thermodynamics, and its calculations are simpler than often turbulent flows. However, there are still…

This State of Technology Report is a compendium of the latest trends articles, back-to-basics tutorials, application stories and product solutions recently published in the pages of Control—compiled by the editors and all together here in one convenient eBook.

Despite ongoing advances in instrumentation technology, specifying a flowmeter or level gauge that will reliably perform over the anticipated range of process conditions often remains a complex and subtle engineering task.
Dozens of niche…

Process plants and related facilities such as tank farms are filled with vessels, tanks and similar storage units, and most of these units could benefit from a system to measure, monitor and view inventory on a near real-time basis. "Logistical…

Additional information and wireless connectivity are further improving productivity, reliability and efficiency.

Like other facilities that have been using the HART Communication Protocol for any amount of time, previous recipients of the HART Plant of the Year Award have been busy reaping even more of the benefits the technology provides. These benefits…

BLH Nobel Introduced a System That Quickly and Easily Checks Weighing Systems for Wiring and Mechanical Faults

Load cell weighing systems solve some of the knottiest problems in batch and level control by directly measuring masses of solids and liquids as they're accumulated, dispensed or conveyed. But the load cells must be installed and wired properly, and the load structure must be engineered and constructed correctly to distribute the measured load as axial forces on the cells. What appear on the surface to be simple wiring and construction tasks have caused more than a few problems during commissioning and maintenance due to miswired or poorly made connections, distorted or binding structures, incorrectly installed load cells or rigid connections to adjacent equipment.
Such problems often are not found until a new installation is being…

Recent

Greg McMillan and Stan Weiner Speak with Electrochemical Measurements Expert Jim Gray About the pH Electrode and Its Full Potential as a Measuring Tool

Stan: A measurement is only as good as its calibration. The pH electrode has by far the greatest sensitivity and rangeability of any measurement in the process industry. The electrode can function well in a wide spectrum of process fluids and…

This month, the editors of Control browse the web to get you the latest online resources on loop control. Here's how you can stay in the loop!

This System Is Closed
This is a basic tutorial on closed-loop control systems. It covers the basic definitions and descriptions of how closed-loop systems work, a discussion of closed-loop summing points and how to use them, transfer functions, multi-loop closed-loop systems and closed-loop motor control. The direct link is www.electronics-tutorials.ws/systems/closed-loop-system.html.Electronics Tutorials www.electronics-tutorials.ws
PID Control
VeriCal in-situ calibration verification This is a basic discussion, with illustrations, of the principles of Proportional, Integral, Derivative (PID) and how it is used with controllers. It also covers tuning rules and starting settingf for common control loops. The direct link is at…

Through the looking glass of emerging technologies.

How might we expect emerging technologies to play out in the world of process control? Successfully predicting the future is difficult at best, so we sought out and consulted with industry visionaries and long-term planners to see where there is…

A Frost & Sullivan report, "Programmable Logic Controllers Market," finds that the market earned revenues of $10.37 billion in 2013 and estimates this will reach $14.58 billion in 2018.

According to analyst firm Frost & Sullivan, the global PLC market, which witnessed a strong decline in growth in 2012 due to the uncertain economic scenario in the developed world, has bounced back. Since 2013, it has witnessed positive growth, particularly in the Asia-Pacific region, where the rebound has been fueled by increased activity, especially in the construction, water and wastewater and power industries.
A Frost & Sullivan report, "Programmable Logic Controllers Market," finds that the market earned revenues of $10.37 billion in 2013 and estimates this will reach $14.58 billion in 2018.
In Europe, the need to enhance efficiency and comply with regulations, as well as improve safety and control capabilities, are driving…

ABB is participating in the ISA106 committee's efforts to go beyond layers of protection, and integrate sequential and procedural safety methods into process control applications

Process safety is about a lot more than armoring up against threats and mishaps, and it's time that many process operators, engineers and managers knew it.
Process manufacturers have long used hazards and operability (HAZOP) studies, layers of…

Control Engineering Branches Out to Manage Critical Business Variables Such as Profitability, Risk, Asset Management and Cybersecurity

Most process engineers I talk to look back on the 1970s and 1980s as the heyday of control engineering, and in many ways it was. More engineers were focused on the applications of real-time control theory then than now. And when you look at how far…

The Latest in Computing Technology Is Here

VERSATILE AUTOMATION COMPUTERS These four new computers are designed for the challenging requirements of the machine automation industries. UNO-3073 and UNO-3073GL have Intel Celeron 1.1- MHz and 1.0-MHz processors; UNO-3083G and UNO-3085G have Intel Core i7 2.2- MHz processors. They have up to five PCI/PCIe expansion slots and support high-speed PCIe x16, x8, x4 and x1 cards and legacy PCI cards. Advantech Industrial Automation Group 800-205-7940www.advantech.com/ea
GAME-CHANGING PACs PACSystems RXi, a new control and computing platform, is designed for the needs of the industrial Internet. The core of the product family is a COM Express architecture with multi-core CPUs. Its configurations are unique in the industry, and able to…

New robot innovations are changing the way manufacturers load and unload machines

Say good-bye to expensive manual machine loading and unloading in harsh environments. Say hello to robotics.
If you haven’t been introduced already, robots are designed to help with reducing production costs, increasing flexibility and improving…

Since the goal is to control loop stability, the choice that gives you the best chance of that is the one to make.

Question:
Is there some general rule on when we should use =% (equal percentage) and when linear control valves? I know that the determining factor is the inherent flow characteristic, the flow vs. lift at constant pressure drop, or something like…

After six decades of developing on/off valve automation solutions, it might seem logical for Emerson Process Management to pause and take a well-deserved breather. But anyone who thinks that doesn't know how this company works. Just like the…

Smart Drives, Mechatronics, Variable-Speed Drives and More Power Options

MEDIUM-VOLTAGE AC DRIVE MV1000 medium-voltage ac drives combine compact modular design, high efficiency and a good MTBF rate. Smart Harmonics technology reduces input total harmonic distortion to less than 2.5% without filters, which exceeds the requirements of IEEE519-1992. It also provides galvanic isolation between power input and output, and uses two 5-V step bridges per phase to generate a 17-level, line-to-line voltage output delivered to the motor. Yaskawa800-927-5292
VSD WITH SMARTSAltivar Process is a range of VSDs from 1 hp to 1,500 hp that come with embedded process knowledge, configurable on-board dashboards and a graphical HMI display. An advanced, secure, integrated web server lets operators access technical…

Through the looking glass of emerging technologies.

How might we expect emerging technologies to play out in the world of process control? Successfully predicting the future is difficult at best, so we sought out and consulted with industry visionaries and long-term planners to see where there is…

101 solutions and strategies for navigating the complex field of membrane switch design.

Pannam Imaging published 101 solutions and strategies for navigating the complex field of membrane switch design to help their readers and customers understand the many facets of membrane switch technology. The extensive lists of tips includes membrane switch applications, user interface design and human-machine interaction, the use of PCBs (printed circuit boards), backlighting options and other technologies, tactile feedback and other design considerations, and membrane switch and electronics industry trends.
With Pannam Imaging's permission, we brigng you the first ten. At the end of the article you willl have a link to access all 101 tips.
Membrane switches are used in many applications that you use every day. “Keypads have…

When instruments "talk" back, their messages become priority. Don't want to miss the alert saving you from an a plant shutdown.

As we're hurried forward into the promised new "Industrial Internet of Things" - the "IIoT," a.k.a. "pervasive sensing," will we find the presumed wealth of previously hidden information useful or interesting? Surely there will be something I care…

The GX and GP Products Are the First of a New SmartDAC+ Product Family

Yokogawa has released the GX and GP Series of digital data acquisition systems, products that go far beyond functionality of the original paperless recorder. Complementing Yokogawa's DXA Advanced R4 series, the GX and GP bring some features that are…

Recent

Because Big Data is Really More of the Same Data, Engineers and Other End Users Find Ways to Take Advantage of New Sources of Intelligence

I'm sorry to be a downer at the start of a shiny New Year, but I'm continually reminded that most new and unfamiliar technical concepts are just more of the same old concepts. Big data is really more of the same data. The Internet of Things (IoT)…

Download this free technology report and get the latest information from connectors and cordsets to intrinsic safety and power supplies.

In this exclusive, 35-page eBook from the editors of Control you will find an exclusive collection of our best technology trends, back-to-basics tutorials and application stories on all things I/O.
The technology report is divided in three section:…

Diagnosing a signaled instrument failure is tricky, time-consuming and usually is called for at a most inconvenient time, but better diagnostics are making the task easier.

Physical Layer Diagnostic Improvements
Why is it, after weeks of seemingly trouble-free plant operation, the phone rings on the holiday weekend when the goose is in the oven and the table is set for dinner? Fortunately for me, the crew on shift was…

A badly designed network is often the weakest link in the system.

IoT's Weakest Link
A common conversation among many industrial networking specialists these days revolves around whether we should be distinguishing between wired and wireless networks. WINA, of which I am chairman, is one organization taking a…

A report published by Smart Industry says that the future of manufacturing plants will be based on the efficiency capabilities smart tools are bringing to the table.

A report published by Smart Industry says that the future of manufacturing plants will be based on the efficiency capabilities smart tools are bringing to the table.
Bringing the Industrial Internet to hand-held devices on the factory floor, enhances productivity, production quality, and work safety.
Theresa Woodiel, National Instruments' Global Campaign Manager, Embedded Systems, recently spoke with Smart Industry and talked about how the company is helping Airbus optimize their factory floor. They are upgrading Airbus's sensors, software and data technology, putting the power and control on individual workers' hands. Smart tools are a key element in the process, communicating with both the factory-wide infrastructure, with the individual…

Download this free technology report and get the latest information from connectors and cordsets to intrinsic safety and power supplies.

In this exclusive, 35-page eBook from the editors of Control you will find an exclusive collection of our best technology trends, back-to-basics tutorials and application stories on all things I/O.
The technology report is divided in three section:…

Mobility's True Value Lies in Enabling New Possibilities

Rockwell Automation takes seriously the needs of its users to access information when on the go. For years now, they've offered the ability to send text or email notifications to mobile devices or replicate in-plant or desktop user interfaces on…

Recent

Download this free technology report and get the latest information from connectors and cordsets to intrinsic safety and power supplies.

In this exclusive, 35-page eBook from the editors of Control you will find an exclusive collection of our best technology trends, back-to-basics tutorials and application stories on all things I/O.
The technology report is divided in three section:…

$5-billion transaction will more than double Olin’s scale

The boards of directors of Dow Chemical of Midland, Michigan, and Olin Corporation of Clayton, Missouri, have unanimously agreed to a deal by which Dow will separate a significant portion of its chlor-alkali and downstream derivatives businesses and…

Version 6 of System 800xA process control system offers a host of new capabilities, integrates with more application areas, and provides more useful functions for users.

Some Swiss Army knives just get better—to the point where it seems they can go anywhere and accomplish almost anything.
System 800xA (eXtended Automation) is one of these universally helpful tools; and its new version 6 (v6) is continuing this tradition by helping users with many new and improved features via new avenues to help people, equipment and systems cooperate more effectively. This new version is available now for new projects. Pricing will be available in April, and it will launch for upgrade projects in June.
"Anything you can bring in with System 800xA is available to all systems," explained Roy Tanner, ABB's global product marketing manager for 800xA. "Users can call up devices and data from multiple suppliers and show…

Coca-Cola and GE Lighting Use Proficy Workflow, Historian, iFix HMI SCADA and Portal Software to Streamline Lighting and Refreshment Production

Seeing is believing, and bringing operational information into the light makes it usable by everyone in an enterprise—allowing them all to make faster, more productive decisions.
This enhanced awareness was especially useful at GE Lighting,…

$5-billion transaction will more than double Olin’s scale

The boards of directors of Dow Chemical of Midland, Michigan, and Olin Corporation of Clayton, Missouri, have unanimously agreed to a deal by which Dow will separate a significant portion of its chlor-alkali and downstream derivatives businesses and…

Find out what certification ABB Canada received and what B&B ELectronics' new name is.

ABB's operations in Canada have been certified by TÜV SÜD as having in place and applying a functional safety management system (FSMS) for the design and engineering of safety instrumented system (SIS) projects in accordance with industry good practice safety standards. These standards include IEC 61508 and IEC 61511 for the integration and implementation of safety instrumented systems. Networking technology provider B&B Electronics has changed its name to B+B SmartWorx. While continuing to develop mission-critical network connectivity technology for remote or demanding environments, B+B SmartWorx is expanding into the emerging Internet of Things market and embedding intelligence throughout the network connectivity stack from edge…

The number of global Internet users will double to 4 billion by 2020, with ever more of these users—about three quarters of them—living in emerging economies. Along with these rising numbers will come an exponential increase in cybersecurity…

What do 9/11, the Detroit Bomber and ICS Security Have in Common?

By Walt Boyes, Editor in Chief
In his "Unfettered" blog post, "What do 9/11, the Detroit Bomber and ICS Security Have in Common," Joe Weiss makes a really good point: The result of all governments' responses to the Dec. 25 incident on the approach…

Recent

Will Electronic Marshalling Mean the End of the "Bespoke" Enclosure?

Unlike clothing fashions, enclosure styles don't change a lot from year to year. A 40-year-old enclosure doesn't stand out like your dad's leisure suit. After all, a big metal box is pretty much a big metal box, even with the added glitz of…

Drowning in Data, Starving for Info-Part 3

More Chat with Randy Reiss, Who Helped Develop a Data Analytics System for Batch Processes for the New Opportunities Created by the Federal Drug Administration's Process Analytical Technology (PAT) Initiative

Greg McMillan and Stan Weiner bring their wits and more than 66 years of process control experience to bear on your questions, comments, and problems. Write to them at controltalk@putman.net.

Stan: How do you quantify the effect of unmeasured disturbances?

Randy: The analysis is based on measurements. Unmeasured disturbances come in the form of variability in a QA value that is uncorrelated to the measurements. For the online principal component analysis (PCA), the quality assurance (QA) value is not considered, and, therefore, there would be no indication. For the projection to latent structures—also known as partial least squares (PLS)—the prediction simply would be wrong. In short, there is no quantification of unmeasured disturbances.

Greg: How do you set the thresholds for deviations?

Randy: A model does have an alpha level parameter that indicates how sensitive the model is. If that parameter is set to .01, then anything outside of 99% of the bell curve is considered a deviation. A more common alpha level is the .05 or 95% exhibited by the bell curve.

Stan: How do you determine if a PCA or PLS result is wrong?

Randy: The PCA is wrong if it generates so many false positives or false negatives that the operation personal ignore it; then the analysis is not doing its job. For PLS, if the predictions do not reasonably match the lab analysis QA, then PLS is not doing its job. In short, if the PCA or PLS are not adding value to your daily operation, then something is wrong.

Greg: How do you find the most important contributions for PCA and PLS (drill down)?

Randy: PCA contributions are the amount each measurement contributes to the overall statistic, either the T^2 statistic or error statistic (Q or SPE). Thus, when a fault is detected by the statistic exceeding the upper control limit (UCL), the contributions can be used to see which tags are causing the fault. The idea of multivariate analysis is that more than one measurement may be causing the fault. Thus, when looking at contributions, the operator may not see a single measurement contribution that exceeds the UCL, but a combination of measurements that are larger than the rest, but still well below the UCL.

This is where process knowledge comes in. The operator or engineer needs to be able to consider the measurements that are identified as outliers and associate them to a process fault. One method may be to bring up a trend of the measurements for this equipment unit and focus on the tags identified by PCA and ask, "What is going wrong?" The idea is to assess a cause from the correlations provided by the analysis. PCA is an early fault detection tool, but does not diagnose the fault for you. PLS contributions may or may not be available in some toolsets.

When a predicted product quality goes bad, it is natural to ask what caused the prediction to indicate a decrease in product quality. However, the prediction calculation only looks at the major correlations between measurements and modeled QA. Thus, the contributing tags for a prediction may not portray the overall picture of the fault, but it may be useful in pointing out a major factor. Regardless, it is always important to refer to the associated PCA charts for a larger view of the problem. In short, a PLS analysis only works on data defined in the model, and PCA reports on what is in the model and what is happening outside of the model.

Stan: Is there anything that can be done to verify causal relationships or track down root causes?

Randy: The very nature of statistical modeling is correlations, and any causal relationship must be verified. To this extent, analytics are just indicators and should not be used to explicitly define causes for process characteristics.

There is no substitute for a process engineer with a good understanding of the process. The analytics should add to the engineer's process knowledge base and understanding, but should not be used as a de facto tool for defining casual relationships in the process. In practice, if a modeled process shows a relationship between certain measurements and product quality during a period in the batch, it's worth investigating. Periods when the PLS confidence interval significantly narrows may be a good indicator that a critical stage of processing is occurring with regards to end-of-batch product quality. Likewise, if the un-normalized upper control limit (UCL) in the PCA analysis dips, it means the modeled batches were very similar during this period. This information can be used as a starting point for process improvements that may result in better product consistency and quality.

Stan: How do you view the need for better data visualization and the prospects of using parallel coordinates?

Randy: I tend to see data visualization as what you do when you don't have multivariate statistics; that is, data visualization has the same intent of multivariate statistics, but lacks the mathematical rigor. Instead, it is left up to the viewer to make correlations. The data visualization is supposed to point the viewer in the right direction, but ultimately it is the viewer deciphering the meaning of multivariate data. The whole point of statistics is that humans cannot distinguish correlations as well as mathematical rigor. A statistic will more definitively group the most similar objects. Data visualization is useful when patterns are apparent.

However, it may be the case that patterns are not apparent or misleading. I agree that better data visualization can help see patterns and outliers, but it only goes so far and relies heavily on human intuition. However, the technique of quantized generalized parallel coordinate plots (GPCP) looks quite interesting. It is more informative than a normal parallel plot, as it projects the data onto a basis for a continuous 2D function. In this sense, it transforms the whole batch into a single line. Obviously, the basis will determine what the continuous 2D function will be telling us about the batch. This technique may be useful for engineers. It could prove useful for tracking down the source of disturbances and interactions via common frequencies.

However, I do not see how any of this could be applicable to operators as it is just too abstract. You will never be able to convince or train an operator to read the GPCP graph.

Maybe there is a way to use parallel plots with analytics. What about plotting the statistics on a parallel plot? Plot the PCA statistics (T^2 and Q) and the PLS statistics (prediction and confidence interval). Overlay these four variables for all time slices of a batch, or maybe look at the same time slice of many batches. Maybe that would be interesting. Is the prediction high when the T^2 and Q statistics are high? Because some of these statistics are mathematically dependent, it just might help people understand the relationships. There may be some value in using parallel plots for viewing the various statistics in analytics.

Greg: We conclude our visit with Randy with his latest "Top 10 List" with some awfully familiar sounding songs.

Top 10 Songs for the Data Analytics Project

10. Does Anybody Really Know What Batch This Is?9. Another Batch Bites the Dust8. We Gotta Get Data Out of this Process [If It's the Last Thing We Ever Do]7. Good Batches, Bad Batches [You Know I've Had My Share]6. Correlation Dreaming5. Changes in Variables, Changes in Attitudes4. [There Must Be] 50 Measurements to Model your Process3. This Project's So Bright, I Gotta Wear Shades2. Gimme All Your Data [All Your QA and ICs Too]1. In-A-Planta-Da-Vida

Data, data, it's all about the data. Nothing makes a control system fail faster than a failure of the data acquisition system. Walt Boyes, Control's editor in chief, takes you back to the basics on data acquisition systems and software.